Red Seal Boilermaker cheat sheet

Lockout/tagout: isolate all energy sources (electrical, pneumatic, hydraulic, steam, gravity/stored), verify zero energy at the point of work before entry; one lock and key per worker.

Confined space entry requires a permit, atmospheric test (oxygen 19.5–23.5%, LEL below 10%, H2S and CO within limits), a standby attendant, and continuous or periodic re-testing.

Hot work permit is required where sparks can reach combustibles; a fire watch must remain 30 minutes after hot work ends (CSA/NFPA practice).

Fall protection is required at 3 m in general construction; a full-body harness with shock-absorbing lanyard limits arrest force to about 8 kN and requires 100% tie-off above anchor.

Cylinder storage: oxygen and fuel gas separated by 6 m or a 30-minute fire-rated barrier; cylinders upright, valve caps on, secured, away from heat and grease.

Manual lifting limit guideline: load within about 25 kg close to the body; above that use mechanical aids or two-person lift.

Hearing protection mandatory at 85 dBA TWA; noise doubles roughly every 3 dB, so 95 dBA cuts allowable exposure time to about 4 hours.

WHMIS/GHS: every controlled product needs a label and SDS; SDS sections 4–8 cover first aid, firefighting, accidental release, and handling/storage.

Scaffold rules: 3:1 height-to-base ratio for supported scaffolds (4:1 for mobile), guardrails at 0.9–1.1 m, toe boards, and full planking.

True length of an inclined line is found by rotating it parallel to a reference plane; the hypotenuse of a right triangle with the rise and run gives the same result.

Parallel line development applies to prisms and cylinders: divide the girth into equal divisions, project to the elevation, and transfer heights to the stretch-out.

Radial line development applies to cones and pyramids: locate the apex, use the slant height as radius, and step off the true-length divisions along the arc.

Triangulation is used for transition pieces (square-to-round, offset cones): divide surfaces into triangles, find true lengths of each side, and build the pattern triangle by triangle.

Bend allowance = (π/180) × bend angle × (inside radius + K × thickness); K-factor is typically 0.33–0.5 depending on R/T ratio.

Neutral axis for a bend is about 0.33–0.5 of thickness from the inside face; use it for flat-pattern length rather than inside or outside dimensions.

Allow for shrinkage and weld take-up: butt welds consume roughly 2–3 mm per pass of length; add seam allowances before cutting.

Oblique cylinder development uses an ellipse: the stretch-out length is πD and each division height is read from the elevation perpendicular to the axis.

Template material must match the surface: heavy paper for flat plate, shim stock or Mylar for curved or vertical surfaces; scribe lines with a sharp scriber and layout dye.

Oxy-fuel cutting: preheat to ignition temperature, then a cutting oxygen jet oxidizes the steel; kerf widens with thicker plate and faster travel gives more drag.

Cut quality is judged by drag lines, kerf width, dross, and squareness; a slight drag angle of 0–5° is acceptable, excessive lag indicates too fast a travel speed.

Plasma cutting handles stainless and aluminum; cut quality depends on amperage, gas selection, standoff, and travel speed; dross indicates speed or gas mismatch.

Minimum bend radius for mild steel is roughly 1× thickness (temper-dependent); aluminum needs larger radii to avoid cracking.

Springback must be compensated: overbend by the measured springback angle, which increases with yield strength and R/T ratio.

Rolling a cylinder: set the rolls slightly tighter than final radius, pass in increments, and check with a template; pre-bend the ends to avoid flat spots.

Press brake tonnage ≈ (1.42 × tensile strength × thickness² × length) / (1000 × die opening) in consistent units; narrow dies raise tonnage and reduce inside radius.

Hole quality: drilled holes are rounder than punched; for structural connections, hole diameter is typically bolt diameter + 2 mm (or 1/16 in) for punched, + 1.5 mm for drilled.

Edge preparation: bevel angles of 30° per side (60° included) for V-groove butt welds; root face 1.5–3 mm and root gap 2–4 mm depending on process.

SMAW electrode classification E7018: E = electrode, 70 = 70 ksi minimum tensile, 1 = all-position, 8 = low-hydrogen, iron-powder coating; store in a holding oven at 120–150 °C.

GMAW transfer modes: short-circuit (low current, thin material), globular (transition), spray (high current, argon-rich gas, deep penetration), and pulsed (controlled spray at low average current).

GTAW uses a non-consumable tungsten electrode and separate filler; DCEN for steel, AC for aluminum to break the oxide, and pure argon or argon/helium shielding.

Preheat is required to slow cooling and prevent hydrogen cracking: carbon equivalent CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15; above 0.4 typically needs preheat.

Post-weld heat treatment relieves residual stress and tempers the HAZ; typical soak at 595–690 °C for carbon steel, held 1 h per 25 mm of thickness.

Weld defects: lack of fusion (low heat input or poor angle), porosity (moisture, grease, or gas flow), undercut (excess current or travel), and slag inclusion (poor cleaning between passes).

Distortion control: balance welds about the neutral axis, use back-step or skip sequence, clamp or fixture, and pre-set the joint in the opposite direction.

Fillet weld size is measured by leg length; throat = 0.707 × leg; minimum size depends on thicker part thickness per CSA W59.

Weld symbols: arrow side vs other side, tail for process, flag for field weld, and supplementary contour and finish symbols above the weld symbol.

Sling tension in a two-leg bridle: tension = (load / 2) ÷ cos(θ/2) where θ is the included angle; at 60° included angle each leg carries about 0.58 × load.

Sling angle effect: capacity falls as the angle from horizontal decreases; at 30° from horizontal, capacity is 50% of the vertical rating.

Working load limit (WLL) = breaking strength ÷ design factor; wire rope slings typically use a 5:1 factor, chain slings 4:1, synthetic web slings 5:1.

Wire rope inspection: reject for broken wires (10 in one lay, or 5 in one strand in one lay), kinks, bird-caging, or diameter reduction over 10%.

Shackle and hook rules: never side-load a hook beyond its rated capacity; use a moused hook or safety latch; shackle pins must be fully seated.

Center of gravity: the load hangs directly below the hook; an off-center pick tilts the load, so tag lines and multi-point picks must account for CG shift.

Rigging math: for a load of W lifted by n vertical legs, each leg carries W/n; with slings at angle α from vertical, each carries W / (n × cos α).

Crane capacity depends on radius, boom length, and configuration; always check the load chart at the actual radius, not the boom tip radius.

Tag lines control rotation; keep personnel out of the fall zone and never stand under a suspended load or in the bight of a line.

Thin-wall hoop stress: σ = PD / (2t); longitudinal stress = PD / (4t); use the higher (hoop) stress for shell thickness design.

ASME Section VIII Div. 1 shell thickness: t = PR / (SE − 0.6P) + corrosion allowance, where S is allowable stress, E joint efficiency (1.0 for full RT, 0.85 spot, 0.7 none).

Joint efficiency depends on radiography: full RT gives E = 1.0, spot RT gives 0.85, no RT gives 0.70 for typical double-welded butt joints.

Hydrostatic test pressure is typically 1.3 × MAWP (adjusted for temperature); test water temperature must be above the brittle fracture transition temperature.

Boiler drum and shell: longitudinal seams carry twice the stress of circumferential seams, so longitudinal seam quality governs design.

Nozzle reinforcement: the area removed by the opening must be replaced by excess shell thickness, nozzle neck thickness, or a reinforcing pad within a defined limit.

Tank shell courses: each course thickness is designed for the head at the bottom of that course; design head = (H − 0.3) m of product (API 650 method).

Relief valve setting must not exceed MAWP; the valve must be sized for the worst-case relieving scenario (fire, blocked outlet, thermal expansion).

Corrosion allowance is added to the calculated minimum thickness and is not counted as strength; it is verified by UT thickness readings at inspection intervals.

Fillet weld capacity = 0.707 × leg × length × allowable stress; for E49 electrodes the factored resistance uses the specified tensile strength and a resistance factor (CSA W59).

Bolted connection: bolt shear capacity = 0.6 × ultimate × area; bearing capacity depends on plate thickness and edge distance; slip-critical joints need pretension.

Edge distance minimum is typically 1.5 × hole diameter for sheared edges and 1.25 × for rolled edges; short edge distances cause tear-out.

Column base plates: bearing pressure under plate = load / area; plate thickness is governed by cantilever bending from the column face.

Beam camber and sweep tolerances: sweep limit about L/1000, camber limit about L/1000, and straightness checked with a string line.

Welded beam-to-column moment connection: complete joint penetration (CJP) groove welds at flanges, often with access holes; weld sequence controls shrinkage and rotation.

Plate girder web stiffeners: bearing stiffeners at supports and load points; intermediate stiffeners control web shear buckling when h/t exceeds limits.

Galvanizing requires vent and drain holes (minimum ~12 mm) at high points and low points, and avoids overlapping surfaces closer than 2 mm.

Structural fit-up tolerances: root gap 2–4 mm, misalignment not more than 10% of thickness (max 3 mm) for butt joints in primary members.

Pipe schedule vs wall: Schedule 40 and 80 are nominal; actual wall = OD − ID ÷ 2; use ASME B36.10 for wall thickness tables.

Bend radius rule: long-radius elbow = 1.5 × NPS; short-radius = 1.0 × NPS; miter bends are limited by pressure and code (ASME B31.3).

Pipe expansion: ΔL = L × α × ΔT; for carbon steel α ≈ 12 × 10⁻⁶ /°C, so 30 m of pipe at 100 °C rise grows about 36 mm.

Expansion loops and guides: anchors and guides direct movement into loops or offsets; a loop must be sized to absorb the calculated thermal growth without overstress.

Hydro test of piping is typically 1.5 × design pressure (ASME B31.3) with test water below the brittle transition temperature and vents at high points.

Flange bolt-up: use a star or crisscross pattern in stages (typically 30%, 60%, 100% of torque); gasket seating stress and bolt preload must be balanced.

Tank nozzle orientation and shell course layout follow API 650: shell courses are laid out from the bottom up, with staggered vertical seams between adjacent courses.

Isometric drawings show pipe routing, fittings, valves, and coordinates; line numbers encode size, service, material class, and insulation.

Piping support types: rigid (anchor, rest), spring hangers for vertical movement, and guides for axial movement; never use a valve as a support.

Visual inspection (VT) is the first line of QC; check weld profile, undercut, spatter, fit-up, and dimensional tolerances before any NDT.

Radiographic testing (RT) detects volumetric defects (porosity, slag, incomplete penetration); sensitivity improves with smaller source size and proper IQI selection.

Ultrasonic testing (UT) detects planar defects (cracks, lack of fusion) and measures thickness; calibration blocks and couplant are essential.

Magnetic particle testing (MT) detects surface and near-surface discontinuities in ferromagnetic material; use AC for surface, DC for deeper indications.

Dye penetrant testing (PT) detects surface-breaking defects in non-porous materials; clean, apply penetrant, dwell, remove, apply developer, and inspect.

Hydrostatic test: hold at test pressure, inspect for leaks, then reduce to design pressure before final inspection; record pressure, temperature, and duration.

Weld acceptance criteria: undercut limit typically 0.5 mm deep or 10% of thickness (CSA W59); porosity limits depend on joint type and service.

Dimensional checks: use a tape, level, plumb bob, and laser for alignment; record as-built dimensions against drawing tolerances.

NDT personnel certification follows SNT-TC-1A or CP-189; Level II can perform and interpret, Level III can develop procedures and certify.

Lockout/tagout: isolate all energy sources (electrical, pneumatic, hydraulic, steam, gravity/stored), verify zero energy at the point of work before entry; one lock and key per worker.

Confined space entry requires a permit, atmospheric test (oxygen 19.5–23.5%, LEL below 10%, H2S and CO within limits), a standby attendant, and continuous or periodic re-testing.

Hot work permit is required where sparks can reach combustibles; a fire watch must remain 30 minutes after hot work ends (CSA/NFPA practice).

Fall protection is required at 3 m in general construction; a full-body harness with shock-absorbing lanyard limits arrest force to about 8 kN and requires 100% tie-off above anchor.

Cylinder storage: oxygen and fuel gas separated by 6 m or a 30-minute fire-rated barrier; cylinders upright, valve caps on, secured, away from heat and grease.

Manual lifting limit guideline: load within about 25 kg close to the body; above that use mechanical aids or two-person lift.

Hearing protection mandatory at 85 dBA TWA; noise doubles roughly every 3 dB, so 95 dBA cuts allowable exposure time to about 4 hours.

WHMIS/GHS: every controlled product needs a label and SDS; SDS sections 4–8 cover first aid, firefighting, accidental release, and handling/storage.

Scaffold rules: 3:1 height-to-base ratio for supported scaffolds (4:1 for mobile), guardrails at 0.9–1.1 m, toe boards, and full planking.

True length of an inclined line is found by rotating it parallel to a reference plane; the hypotenuse of a right triangle with the rise and run gives the same result.

Parallel line development applies to prisms and cylinders: divide the girth into equal divisions, project to the elevation, and transfer heights to the stretch-out.

Radial line development applies to cones and pyramids: locate the apex, use the slant height as radius, and step off the true-length divisions along the arc.

Triangulation is used for transition pieces (square-to-round, offset cones): divide surfaces into triangles, find true lengths of each side, and build the pattern triangle by triangle.

Bend allowance = (π/180) × bend angle × (inside radius + K × thickness); K-factor is typically 0.33–0.5 depending on R/T ratio.

Neutral axis for a bend is about 0.33–0.5 of thickness from the inside face; use it for flat-pattern length rather than inside or outside dimensions.

Allow for shrinkage and weld take-up: butt welds consume roughly 2–3 mm per pass of length; add seam allowances before cutting.

Oblique cylinder development uses an ellipse: the stretch-out length is πD and each division height is read from the elevation perpendicular to the axis.

Template material must match the surface: heavy paper for flat plate, shim stock or Mylar for curved or vertical surfaces; scribe lines with a sharp scriber and layout dye.

Oxy-fuel cutting: preheat to ignition temperature, then a cutting oxygen jet oxidizes the steel; kerf widens with thicker plate and faster travel gives more drag.

Cut quality is judged by drag lines, kerf width, dross, and squareness; a slight drag angle of 0–5° is acceptable, excessive lag indicates too fast a travel speed.

Plasma cutting handles stainless and aluminum; cut quality depends on amperage, gas selection, standoff, and travel speed; dross indicates speed or gas mismatch.

Minimum bend radius for mild steel is roughly 1× thickness (temper-dependent); aluminum needs larger radii to avoid cracking.

Springback must be compensated: overbend by the measured springback angle, which increases with yield strength and R/T ratio.

Rolling a cylinder: set the rolls slightly tighter than final radius, pass in increments, and check with a template; pre-bend the ends to avoid flat spots.

Press brake tonnage ≈ (1.42 × tensile strength × thickness² × length) / (1000 × die opening) in consistent units; narrow dies raise tonnage and reduce inside radius.

Hole quality: drilled holes are rounder than punched; for structural connections, hole diameter is typically bolt diameter + 2 mm (or 1/16 in) for punched, + 1.5 mm for drilled.

Edge preparation: bevel angles of 30° per side (60° included) for V-groove butt welds; root face 1.5–3 mm and root gap 2–4 mm depending on process.

SMAW electrode classification E7018: E = electrode, 70 = 70 ksi minimum tensile, 1 = all-position, 8 = low-hydrogen, iron-powder coating; store in a holding oven at 120–150 °C.

GMAW transfer modes: short-circuit (low current, thin material), globular (transition), spray (high current, argon-rich gas, deep penetration), and pulsed (controlled spray at low average current).

GTAW uses a non-consumable tungsten electrode and separate filler; DCEN for steel, AC for aluminum to break the oxide, and pure argon or argon/helium shielding.

Preheat is required to slow cooling and prevent hydrogen cracking: carbon equivalent CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15; above 0.4 typically needs preheat.

Post-weld heat treatment relieves residual stress and tempers the HAZ; typical soak at 595–690 °C for carbon steel, held 1 h per 25 mm of thickness.

Weld defects: lack of fusion (low heat input or poor angle), porosity (moisture, grease, or gas flow), undercut (excess current or travel), and slag inclusion (poor cleaning between passes).

Distortion control: balance welds about the neutral axis, use back-step or skip sequence, clamp or fixture, and pre-set the joint in the opposite direction.

Fillet weld size is measured by leg length; throat = 0.707 × leg; minimum size depends on thicker part thickness per CSA W59.

Weld symbols: arrow side vs other side, tail for process, flag for field weld, and supplementary contour and finish symbols above the weld symbol.

Sling tension in a two-leg bridle: tension = (load / 2) ÷ cos(θ/2) where θ is the included angle; at 60° included angle each leg carries about 0.58 × load.

Sling angle effect: capacity falls as the angle from horizontal decreases; at 30° from horizontal, capacity is 50% of the vertical rating.

Working load limit (WLL) = breaking strength ÷ design factor; wire rope slings typically use a 5:1 factor, chain slings 4:1, synthetic web slings 5:1.

Wire rope inspection: reject for broken wires (10 in one lay, or 5 in one strand in one lay), kinks, bird-caging, or diameter reduction over 10%.

Shackle and hook rules: never side-load a hook beyond its rated capacity; use a moused hook or safety latch; shackle pins must be fully seated.

Center of gravity: the load hangs directly below the hook; an off-center pick tilts the load, so tag lines and multi-point picks must account for CG shift.

Rigging math: for a load of W lifted by n vertical legs, each leg carries W/n; with slings at angle α from vertical, each carries W / (n × cos α).

Crane capacity depends on radius, boom length, and configuration; always check the load chart at the actual radius, not the boom tip radius.

Tag lines control rotation; keep personnel out of the fall zone and never stand under a suspended load or in the bight of a line.

Thin-wall hoop stress: σ = PD / (2t); longitudinal stress = PD / (4t); use the higher (hoop) stress for shell thickness design.

ASME Section VIII Div. 1 shell thickness: t = PR / (SE − 0.6P) + corrosion allowance, where S is allowable stress, E joint efficiency (1.0 for full RT, 0.85 spot, 0.7 none).

Joint efficiency depends on radiography: full RT gives E = 1.0, spot RT gives 0.85, no RT gives 0.70 for typical double-welded butt joints.

Hydrostatic test pressure is typically 1.3 × MAWP (adjusted for temperature); test water temperature must be above the brittle fracture transition temperature.

Boiler drum and shell: longitudinal seams carry twice the stress of circumferential seams, so longitudinal seam quality governs design.

Nozzle reinforcement: the area removed by the opening must be replaced by excess shell thickness, nozzle neck thickness, or a reinforcing pad within a defined limit.

Tank shell courses: each course thickness is designed for the head at the bottom of that course; design head = (H − 0.3) m of product (API 650 method).

Relief valve setting must not exceed MAWP; the valve must be sized for the worst-case relieving scenario (fire, blocked outlet, thermal expansion).

Corrosion allowance is added to the calculated minimum thickness and is not counted as strength; it is verified by UT thickness readings at inspection intervals.

Fillet weld capacity = 0.707 × leg × length × allowable stress; for E49 electrodes the factored resistance uses the specified tensile strength and a resistance factor (CSA W59).

Bolted connection: bolt shear capacity = 0.6 × ultimate × area; bearing capacity depends on plate thickness and edge distance; slip-critical joints need pretension.

Edge distance minimum is typically 1.5 × hole diameter for sheared edges and 1.25 × for rolled edges; short edge distances cause tear-out.

Column base plates: bearing pressure under plate = load / area; plate thickness is governed by cantilever bending from the column face.

Beam camber and sweep tolerances: sweep limit about L/1000, camber limit about L/1000, and straightness checked with a string line.

Welded beam-to-column moment connection: complete joint penetration (CJP) groove welds at flanges, often with access holes; weld sequence controls shrinkage and rotation.

Plate girder web stiffeners: bearing stiffeners at supports and load points; intermediate stiffeners control web shear buckling when h/t exceeds limits.

Galvanizing requires vent and drain holes (minimum ~12 mm) at high points and low points, and avoids overlapping surfaces closer than 2 mm.

Root gap 2–4 mm, misalignment not more than 10% of thickness (max 3 mm) for butt joints in primary members.

Pipe schedule vs wall: Schedule 40 and 80 are nominal; actual wall = OD − ID ÷ 2; use ASME B36.10 for wall thickness tables.

Bend radius rule: long-radius elbow = 1.5 × NPS; short-radius = 1.0 × NPS; miter bends are limited by pressure and code (ASME B31.3).

Pipe expansion: ΔL = L × α × ΔT; for carbon steel α ≈ 12 × 10⁻⁶ /°C, so 30 m of pipe at 100 °C rise grows about 36 mm.

Expansion loops and guides: anchors and guides direct movement into loops or offsets; a loop must be sized to absorb the calculated thermal growth without overstress.

Hydro test of piping is typically 1.5 × design pressure (ASME B31.3) with test water below the brittle transition temperature and vents at high points.

Flange bolt-up: use a star or crisscross pattern in stages (typically 30%, 60%, 100% of torque); gasket seating stress and bolt preload must be balanced.

Tank nozzle orientation and shell course layout follow API 650: shell courses are laid out from the bottom up, with staggered vertical seams between adjacent courses.

Isometric drawings show pipe routing, fittings, valves, and coordinates; line numbers encode size, service, material class, and insulation.

Piping support types: rigid (anchor, rest), spring hangers for vertical movement, and guides for axial movement; never use a valve as a support.

Visual inspection (VT) is the first line of QC; check weld profile, undercut, spatter, fit-up, and dimensional tolerances before any NDT.

Radiographic testing (RT) detects volumetric defects (porosity, slag, incomplete penetration); sensitivity improves with smaller source size and proper IQI selection.

Ultrasonic testing (UT) detects planar defects (cracks, lack of fusion) and measures thickness; calibration blocks and couplant are essential.

Magnetic particle testing (MT) detects surface and near-surface discontinuities in ferromagnetic material; use AC for surface, DC for deeper indications.

Dye penetrant testing (PT) detects surface-breaking defects in non-porous materials; clean, apply penetrant, dwell, remove, apply developer, and inspect.

Hydrostatic test: hold at test pressure, inspect for leaks, then reduce to design pressure before final inspection; record pressure, temperature, and duration.

Weld acceptance criteria: undercut limit typically 0.5 mm deep or 10% of thickness (CSA W59); porosity limits depend on joint type and service.

Dimensional checks: use a tape, level, plumb bob, and laser for alignment; record as-built dimensions against drawing tolerances.

NDT personnel certification follows SNT-TC-1A or CP-189; Level II can perform and interpret, Level III can develop procedures and certify.